The Vibrocone™ crusher is the next generation of crushing technology combining the best of conventional crushing and grinding principles.
The crusher can handle even the first stages of grinding. The whole comminution process is made much more streamlined, with great savings in investment, workload, energy and consequently, money. Material is crushed by means of multiple compressions and a large top size in the feed is accepted just as with a traditional cone crusher. Material is crushed in a thick material bed and exposed to optimal controlled force that can be adjusted, as in high pressure grinding rolls. Material is crushed against material, as in AG and SAG mills.
The Vibrocone™ crusher combines the best of conventional crushing and grinding principles to produce an unprecedented amount of finely crushed product. The particles are not only crushed between the liner surfaces in the crushing chamber; they are also to a higher degree crushed by each other in a high pressure inter-particle crushing action. The result is a crusher moving into the grinding performance area. This breakthrough gives Vibrocone extraordinary potential. With a P50=3mm (1/8”) mill feed, the grinding phase works much more efficiently.
Safety has always been one of the cornerstones in Sandvik's values. While developing Vibrocone™, a number of issues were worked on to achieve Sandvik's ambition of providing the safest equipment on the market The Vibrocone design makes it possible to automatically detect and safely react to uncrushable objects like tramp metal. As uncrushable objects restrict the movement of the mantle the power input will drop immediately. Crushing will continue until the object has passed through. If by chance it gets stuck inside due to its size, the feed will stop. Operation can continue gently at reduced speed and force in order to empty the crushing chamber of material, so that the unwanted object can easily be removed Once operating conditions are set up for the specific application the Vibrocone doesn't normally require any human involvement. Crusher performance and power input as well as wear compensation is supervised and regulated around the clock by the automation. The warning system monitors the crusher and alert the operator there is a malfunction. For example, if an uncrushable object is stuck because it couldn't pass the warning system monitor will alert the operator. In addition there is a historical database with all operating parameters in the control system to assist with performance analysis.
Maintenance procedures from conventional cone crushers are well recognised. For wear liner change, the regulating ring is hydraulically unscrewed and the main shaft is lifted out. In support of achieving Sandvik's safety ambition, Vibrocone has no backing material for fixing the mantle and concave. Additionally, all crushed material areas are separated from any mechanical parts of the machine and the crusher product is discharged via an outlet chute of just 500 x 500 mm. There is also a 360¦ access to the crushing chamber and dust seal from six hatches.
Changing the rules for comminution crushers are typically ten times more energy efficient than mills. By producing a much finer mill feed, Vibrocone also handles the first stages of grinding - in a dry process. Off-loading work from the downstream milling process saves up to 30 per cent energy. Meeting increases in energy prices and environmental regulations greatly benefiting the bottom line. The Vibrocone crusher is in operation at copper, gold and iron ore mine sites, and provides highly increased efficiency in the comminution process. Substantial amounts of energy are saved which opens the door to a better future in mining.